Process for preparing organosilicon prepolymers and polymers

ABSTRACT

A novel organosilicon prepolymer, which is the partial reaction product of (a) a cyclic polysiloxane or a tetrahedral siloxysilane containing at least two hydrosilane groups and (b) a polycyclic polyene having in its rings at least two chemically distinguishable carbon-carbon double bonds, wherein the ratio of carbon-carbon double bonds in the rings of (b) to hydrosilane groups in (a) is greater than 0.5:1 and up to 1.8:1, and at least one of the compounds (a) and (b) has more than two reactive sites, a method for making the organosilicon prepolymer, and a method for preparing an organosilicon polymer therefrom, are disclosed.

This is a divisional of U.S. patent application Ser. No. 07/232,826,filed Aug. 16, 1988, now U.S. Pat. No. 4,902,731, which is acontinuation-in-part of U.S. patent application Ser. No. 07/079,740,filed Jul. 30, 1987 now U.S. Pat. No. 4,900,779, which is acontinuation-in-part of U.S. Pat. No. 06/901,092, filed Aug. 27, 1986,now abandoned.

This invention relates to a new and novel class of organosilicon polymerintermediates and the process of making thermoset and thermoplasticpolymers using the same.

BACKGROUND OF THE INVENTION

A new class of high molecular weight organosilicon polymers which haveexcellent physical, thermal and electrical properties and outstandingresistance to water, and that can be used to prepare shaped articles isdescribed in parent application Ser. Nos. 07/079,740 and 06/901,092.They are thermoset or thermoplastic organosilicon polymers comprisingalternating polycyclic hydrocarbon residues and cyclic polysiloxanes orsiloxysilane residues linked through carbon to silicon bonds.

Preferred organosilicon polymers are the reaction product of (a) acyclic polysiloxane or a tetrahedral siloxysilane containing at leasttwo hydrosilane groups and (b) a polycyclic polyene, wherein the ratioof carbon-carbon double bonds in the rings of (b) to hydrosilane groupsin (a) is greater than 0.5:1 and up to 1.8:1 and at least one of thecompounds (a) and (b) has more than two reactive sites.

U.S. patent application Ser. No. 07/079,740 also describes a method ofpreparing the organosilicon polymers according to the invention which ischaracterized in that it comprises reacting, in the presence of aplatinum-containing catalyst, (a) a cyclic or tetrahedral polysiloxanecontaining at least two hydrosilane groups and (b) a polycyclic polyene,the ratio of carbon-carbon double bonds in (b) to hydrosilane groups inthe rings of (a) being greater than 0.5:1 and up to 1.8:1 and at leastone of the compounds (a) and (b) having more than two reactive sites,and subjecting said polymer to heat to drive the cross-linking to amaximum.

SUMMARY OF THE INVENTION

This invention is directed to heat-curable prepolymers or oligomers(hereafter "prepolymer") which are the partial reaction product of (a) acyclic polysiloxane or a tetrahedral siloxysilane containing at leasttwo hydrosilane groups and (b) a polycyclic polyene having at least twochemically distinguishable carbon-carbon double bonds, wherein the ratioof carbon-carbon double bonds in the rings of (b) to hydrosilane groupsin (a) is greater than 0.5:1 and up to 1.8:1 and at least one of thecompounds (a) and (b) has more than two reactive sites; a process forforming the prepolymers; and a process of forming organosilicon polymerswherein the prepolymer is formed and later cured to form theorganosilicon polymer.

DETAILED DESCRIPTION OF THE INVENTION

Any cyclic polysiloxane or tetrahedral siloxysilane with two or morehydrogen atoms bound to silicon will enter into the reaction. Cyclicpolysiloxanes useful in forming the products of this invention have thegeneral formula: ##STR1## wherein R is hydrogen, a saturated,substituted or unsubstituted alkyl or alkoxy radical, a substituted orunsubstituted aromatic or aryloxy radical, n is an integer from 3 toabout 20, and R is hydrogen on at least two of the silicon atoms in themolecule.

The tetrahedral siloxysilanes are represented by the general structuralformula ##STR2## wherein R is as defined above and is hydrogen on atleast two of the silicon atoms in the molecule.

Examples of reactants of Formula (I) include, e.g., tetramethylcyclotetrasiloxane, pentamethyl cyclopentasiloxane, hexamethylcyclohexasiloxane, tetraethyl cyclotetrasiloxane, cyclotetrasiloxane,tetraphenyl cyclotetrasiloxane, tetraoctyl cyclotetrasiloxane andhexamethyl tetracyclosiloxane.

The most commonly occurring members of this group are the tetra-,penta-, and hexacyclosiloxanes, with tetramethyl tetracyclosiloxanebeing a preferred member. In most cases, however, the material is amixture of a number of species wherein n can vary widely. Generally,commercial mixtures contain up to about 20% (in purer forms as low as2%) low molecular weight linear methylhydrosiloxanes, such asheptamethyltrisiloxane, octamethyltrisiloxane, etc.

Examples of reactants of Formula (II) include, e.g.,tetrakisdimethylsiloxysilane, tetrakisdiphenylsiloxysilane, andtetrakisdiethylsiloxysilane. The tetrakisdimethylsiloxysilane is thebest known and preferred species in this group.

Polycyclic polyenes which can be employed are polycyclic hydrocarboncompounds having at least two non-aromatic carbon-carbon double bonds,which have different chemical reactivities, in their rings. By"chemically distinguishable carbon-carbon double bonds" it is meant thatat least two carbon-carbon double bonds have different chemicalreactivities, i.e., different degrees of reactivity to the silanes and,thus, most of one type of bond will react prior to substantial reactionof the second type. Illustrative are compounds selected from the groupconsisting of dicyclopentadiene, tricyclopentadiene, and methyldicyclopentadiene, and substituted derivatives of any of these.Preferred is dicyclopentadiene.

Two or more polycyclic polyenes can be used in combination. Typically,comonomers will be present in an amount up to 30%, based on the weightof the polymer formulation.

The reactions for forming the prepolymer and for forming a polymer fromthe prepolymer can be promoted thermally or by the addition of ahydrosilation catalyst or radical generators such as peroxides and azocompounds. Hydrosilation catalysts include metal salts and complexes ofGroup VIII elements. The preferred hydrosilation catalysts containplatinum.

The reactions for forming the prepolymer and organosilicon polymerproceed readily in the presence of a platinum-containing catalyst. Thepreferred catalyst, in terms of both reactivity and cost, ischloroplatinic acid (H₂ PtCl₆.6H₂ O). Catalyst concentrations of 0.0005to about 0.05% by weight, based on weight of the monomers, will effectsmooth and substantially complete polymerization. Other platinumcompounds can also be used to advantage in some instances, such as PtCl₂and dibenzonitrile platinum dichloride. Platinum on carbon is alsoeffective for carrying out high temperature polymerizations. Otheruseful platinum catalysts are disclosed in, e.g., U.S. Pat. Nos.3,220,972, 3,715,334 and 3,159,662. An exhaustive discussion of thecatalysis of hydrosilation can be found in Advances in OrganometallicChemistry, Vol. 17, beginning on page 407.

It is possible, by selection of reactants, reactant concentrations andreaction conditions, to prepare polymers exhibiting a broad range ofproperties and physical forms. Thus, it has been found possible toprepare tacky solids, elastomeric materials, and tough glassy polymers.

If thermoset polymers are desired, the ratio of carbon-carbon doublebonds of (b) to hydrosilane groups in (a) is in the range of from about0.7:1 up to about 1.3:1, more preferably from about 0.8:1 up to about1.1:1. The alternating residues form a cross-linked thermoset structure.

If thermoplastic polymers are desired, the ratio of carbon-carbon doublebonds in the rings of (b) to hydrosilane groups in (a) is (i) greaterthan 0.5:1 and up to about 0.7:1 or (ii) in the range of from about1.3:1 up to 1.8:1.

To prepare the thermoset and thermoplastic polymers, several approachesare available. In one approach described in U.S. patent application Ser.No. 07/079,740, the correct relative ratios of reactants and theplatinum catalyst are simply mixed and brought to a temperature at whichthe reaction is initiated and proper temperature conditions arethereafter maintained to drive the reaction to substantial completion(typically, with a ratio of carbon-carbon bonds to hydrosilane groups ofabout 1:1, where 70 to 80% of the hydrosilane groups are consumed).

The initial product of the reaction at lower temperatures, e.g., about50° to about 80° C. is often a prepolymer, which may be in the form of asolid or a flowable, heat-curable liquid, even though the ratio ofcarbon-carbon double bonds to hydrosilane groups is otherwise suitablefor cross-linking. Such prepolymers, analogous to the so-called B-stageresins encountered in other thermoset preparations, can be recovered andsubsequently transferred to a mold for curing.

The prepolymers, including the viscous, flowable liquid prepolymers, arestable at room temperature for varying periods of time, but, uponreheating to an appropriate temperature, e.g., about 100° to about 250°C., they cure to the same types of thermoset polymers as are preparedwhen polymerization is carried out substantially immediately.

The B-stage type prepolymers can be prepared by cooling the reactionmass, following the initial exotherm, to about 30° to 65° C. andmaintaining it at that point for several hours, and then interruptingthe reaction by removing the heat until such time as it is desired tocomplete the transition to a glassy, cross-linked thermoset polymer. Theprepolymers generally have 30 to 65% of the hydrosilane groups reacted,and when liquids are desired preferably about 30 to 50% of thehydrosilane groups reacted. By monitoring the viscosity build-up, thepractitioner can select, for his own purposes, the point at which thepolymerization is to be interrupted.

The basic reaction is fast. However, it is exothermic, and without usingheat removal equipment the formation of the prepolymers is generallycarried out over two to twenty-four hours. In a continuous process withadequate heat removal the reaction can be carried out quickly.

The thermoplastic polymers can normally be ground and shipped to amolder where they will be heated and formed into a shaped article. Thus,while prepolymers can be formed as described above, they are primarilyused when thermoset products are desired.

Although a hydrosilation reaction via the carbon-carbon unsaturation ofthe polycyclic polyene rings and the hydrosilane group is the primarypolymerization and cross-linking mechanism, other types ofpolymerization and cross-linking may also take place as the curingtemperature is increased. These may include, e.g., oxidativecross-linking, free radical polymerization (olefin addition reactions)and condensation of silanols to form siloxane bonds.

The thermoset polymers have a range of utilities, depending upon theirphysical form. Tacky solids are useful as tackifiers in pressuresensitive adhesives and as contact adhesives. They are also useful asstructural adhesives, curable in situ, to form strong bonds due to ahigh affinity of hydrosilane derived silanol groups for polar metalsurfaces, especially oxidized metal surfaces. The elastomericembodiments make excellent potting compounds for electronic applicationssince they can be cured in situ and are insensitive to water.

Thermal properties of the thermoset polymers are also outstanding. Theglass transition temperature (Tg) of a fully cured thermoset polymer isabout 200° C. or higher. Thermal stability is excellent with usuallyless than 10% weight loss at 500° C. during thermogravimetric analysis.At 1100° C. in air, they leave about 50% residue. The thermoset polymersare fire resistant and burn very slowly when subjected to a flame.

A particularly striking property of these thermoset polymers is theirvirtually total insensitivity to water. They have been found to beunaffected by boiling water after extended periods.

The thermoset polymers are also resistant to oxidation and toultraviolet radiation at ordinary temperatures. Above 200° C., oxidativecross-linking of silicon portions of the molecule appears to take place,resulting in the formation of a dark siliceous outer layer. Thisoxidized outer layer appears to impede the oxidative degradation of thepolymer.

The thermoset polymers pyrolyze upon heating to greater than 1000° C. toform a high yield (40-50%) of a ceramic. This high temperatureresistance makes them useful as refractory materials, fire resistantmaterials and ablative materials.

The thermoplastic polymers generally exhibit melting points in the rangeof from about 60° C. to about 130° C. However, when post-cured attemperatures greater than 200° C., some (for instance, those having aratio of carbon-carbon double bonds to hydrosilane groups of 1.45:1.0)exhibit elastomeric characteristics, and, in some instances, they havehigher softening points or exhibit thermoset properties after post-cure.

The thermoplastic polymers range from tacky to hard, non-tacky solidswhich have low melting points. Some of the polymers (e.g., those havinga ratio of carbon-carbon double bonds to hydrosilane groups of1.45:1.0.) exhibit thermoplastic behavior (melt flow) until they areheated to a higher temperature (200° to 300° C.) where they becomethermoset polymers. These can be considered thermoplastic-thermosetpolymers. These materials can be coated on substrates as powders, melts,or solutions and cured to give glass transitions somewhat lower than thepolymers that have mainly thermoset behavior (e.g., those having a ratioof carbon-carbon double bonds to hydrosilane groups of about 0.7:1 toabout 1.3:1).

A number of options exist for incorporating additives into the polymer.Additives such as fillers and pigments are readily incorporated. Carbonblack, vermiculite, mica, wollastonite, calcium carbonate, sand, glassspheres, glass beads, ground glass and waste glass are examples offillers which can be incorporated. Fillers can serve either asreinforcement or as fillers and extenders to reduce the cost of themolded product. Glass spheres are useful for preparing low densitycomposites. When used, fillers can be present in amounts up to about80%. Stabilizers and antioxidants are useful to maintain storagestability of B stage materials and thermal oxidative stability of thefinal product.

Glass or carbon, e.g., graphite, fibers are wetted very well by theliquid prepolymers making them excellent matrix materials for highstrength composite structures. Thus a mold containing the requisitestaple or continuous filament can be charged with the prepolymer and theprepolymer cured to form the desired composite structure. Fiber infabric form can also be employed. In addition, solid thermoplasticpolymers may be melted, poured over such fibers, and heated to formcomposites or thermoplastic polymer powders may be blended with suchfibers and, then, heated to form a composite. Fiber reinforcedcomposites of the polymers of this invention can contain as much as 80%,preferably 30 to 60%, by weight, of fibrous reinforcement, and, whenfully cured, typically exhibit extremely high tensile and flexuralproperties and also excellent impact strength. Other types of fibers,e.g., metallic, ceramic and synthetic polymer fibers, also work well.

The glass filled, thermoset products which have been polymerized to thetough glassy state are characterized by high physical properties, i.e.,high modulus and high tensile strength and good flex properties. Theyare fire resistant, burn very slowly when subjected to a flame, andself-extinguish when the flame is removed.

The following examples are presented to demonstrate this invention. Theyare not intended to be limiting. Therein, all percentages, parts, etc.,are by weight, unless otherwise indicated.

EXAMPLE 1

This example shows preparation of a molded, glass cloth reinforced,article comprising a thermoset polymer by preparing a B stage prepolymerby partially reacting dicyclopentadiene andtetramethylcyclotetrasiloxane (ratio of carbon-carbon double bonds tohydrosilane groups of 1:1), injecting the B stage prepolymer into amold, and heating to complete polymerization.

Chloroplatinic acid (0.0101 g) was charged to a dry 750 ml reactionvessel in a N₂ filled glove bag and the reaction vessel was sealed. Drydicyclopentadiene (26.44 g, 0.2 mole) was charged by syringe. Thismixture was heated at 55° C. for one hour to form adicyclopentadiene/chloroplatinic acid catalyst complex. Drytetramethylcyclotetrasiloxane (24.05 g, 0.10 mole) was added graduallyat 56° C. and an immediate exotherm took the temperature to 174° C. Themixture was cooled to 64° to 65° C. and held there for 1.5 hour. Si²⁹NMR shows that the hydrosilation reaction is about 50% complete at thistime. The low viscosity product was removed from the reaction vessel bysyringe and injected into a teflon coated mold containing glass clothwhich exactly filled the mold cavity. The resin in the mold was degassedat 60° C. under a slight vacuum in a vacuum oven The aspirator vacuumwas manually controlled to keep the resin from foaming out of the mold.The mold was heated in an oven at 68° C. for 18 hours and then at 140°to 150° C. for 3 days. The oven was cooled slowly and the mold unclampedto give a very hard, stiff 5"×5"×1/8" plaque. Samples were cut forrheological, tensile, and flexural property determinations and thefollowing data were obtained:

    ______________________________________                                        60% Glass Cloth,                                                              40% Tetramethylcyclotetrasiloxane/                                            Dicyclopentadiene 1/2                                                         ______________________________________                                        Tensile Strength        23,800 psi                                            Tensile Modulus         1.2 × 10.sup.6 psi                              % Elongation (break)    2.2                                                   Flexural Strength       40,400 psi                                            Flexural Modulus        2.2 × 10.sup.6 psi                              Rockwell R Hardness     119                                                   Glass Transition Temp (Rheometrics)                                                                   160° C.                                        Notched Izod Impact.    10 ft lb/in notch                                     Heat Distortion Temperature (264 psi)                                                                 300° C.                                        ______________________________________                                    

EXAMPLE 2

This example shows preparation of a thermoset polymer by reactingdicyclopentadiene and tetramethylcyclotetrasiloxane with a ratio ofcarbon-carbon double bonds to hydrosilane groups of approximately 1:1.

A dry, N₂ sparged vessel was charged with a stir bar and chloroplatinicacid (0.0021 g). The vessel was capped and charged withdicyclopentadiene (20.12 g, 0.152, mole). The resulting mixture wasstirred for thirty minutes at 60° C. Tetramethylcyclotetrasiloxane (18.1g, 0.075 mole) was added and thirty seconds later the reaction mixtureexothermed to 186° C. The reaction mixture was stirred for 16 hours,250° C. for 2 hours and 280° C. for 16 hours to give a brown, glassysolid. The reaction mixture was stirred for 16 hours at 60° C., 24 hoursat 70° C. and 5 hours at 150° C. The mixture was poured into an aluminumpan and cured for 12 hours at 200° C., 2 hours at 225° C., 2 hours at250° C. and 16 hours at 280° C. to give a brown glassy solid.

The thermal stability of the polymer of Example 3 is presented in thefollowing table.

    ______________________________________                                        TGA (20° C./Min.)                                                      Example No.                                                                             10% Wt. Loss (°C.)                                                                    % Residue (1100 °C.)                          ______________________________________                                        2         510            39                                                   ______________________________________                                    

EXAMPLE 3

This example show preparation of a molded, thermoset polymer by reactingdicyclopentadiene and methylcyclotetramethylsiloxane, with a ratio ofcarbon-carbon double bonds to hydrosilane groups of approximately 1:1.

Following the general procedure in Example 2,tetramethylcyclotetrasiloxane (49.76 g, 0.20 mole) was added to a heated(70° C.) mixture of dicyclopentadiene (54.71 g, 0.414 mole) andchloroplatinic acid (0.0209 g). Thirty seconds after thetetramethylcyclotetrasiloxane addition, the reaction mixture exothermedto 170° C. The reaction mixture was stirred for 16 hours at 130° C. andpoured into a teflon coated mold. The sample was cured for 16 hours at150° C. to give an opaque, glassy solid.

EXAMPLE 4

This example show preparation of a molded, glass cloth reinforced,article comprising a thermoset polymer. A B stage prepolymer wasprepared by partially reacting dicyclopentadiene and tetramethylcyclotetrasiloxane in amounts such that the ratio of carbon-carbondouble bonds to hydrosilane groups was 1.1:1. Then, the B stageprepolymer was poured into a mold containing a glass cloth and washeated to complete polymerization.

Following the general procedure in Example 2,tetramethylcyclotetrasiloxane (28.6 g, 0.12 mole) was added to a heated(55° C.) mixture of dicyclopentadiene (34.4 g, 0.26 mole) andchloroplatinic acid (0.0126 g). Thirty seconds after the tetramethylcyclotetrasiloxane addition, the reaction mixture exothermed to 184° C.The reaction mixture was stirred for 2 hours at 80° C. then transferredto a teflon-coated mold containing 50.9 g woven glass cloth. The samplewas cured for 12 hours at 130° C., for eight hours at 160° C., and for16 hours at 180° C. to give an opaque, glassy plaque containing 60.7 wt.% glass cloth. This plaque was further cured in a N₂ flushed oven at200° C., 250° C. and 310° C. for 4 hours at each temperature.

EXAMPLE 5

This example shows preparation of a molded, opaque solid plaquescomprising a thermoset polymer, by preparing a B stage prepolymer bypartially reacting dicyclopentadiene and tetramethyl cyclotetrasiloxane(ratio of carbon-carbon double bonds to hydrosilane groups of 1:1),transferring the B stage prepolymer into a mold, and heating to completepolymerization.

Following the general procedure in Example 2,tetramethylcyclotetrasiloxane (76.36 g, 0.32 mole) was added to a heated(30° C.) mixture of dicyclopentadiene (83.9 g, 0.64 mole) andchloroplatinic acid (0.0148 g). Five minutes after this addition thereaction mixture exothermed to 193° C. The reaction mixture was stirredfor 1 hour at 55° to 70° C., transferred to teflon-coated molds andcured at 145° C. for 18 hours under slight vacuum. The opaque solidplaques were further cured to 285° C. in a N₂ flushed oven.

The polymers of Examples 5 and 6 were further subjected to mechanicalanalysis to determine their glass transition temperature (Tg) andstorage modulus (G') at various temperatures. Results are recorded inthe following table.

    ______________________________________                                        Mechanical Analysis                                                                  Wt. %  Tg     G' (GPa) at T (°C.)                               Example(1)                                                                             Glass    (°C.)                                                                         25   100   140  180  200                             ______________________________________                                        4(a)     60.7     275    2.7  2.2   2.0  1.8  1.6                              (b)     60.7     300    2.5  2.1   1.8  1.5  1.4                             5(a)     0        245    0.8  0.57  0.50 0.43 0.35                             (b)     0        250    0.78 0.60  0.50 0.40 0.35                            ______________________________________                                         (1) (a)Denotes data before water boil. (b)Denotes data after 5 day water      boil.                                                                    

The data in this table demonstrate the relative water insensitivity ofthe organosilicon polymers of this invention. The weight gained after 5days in boiling water was about 0.1%.

EXAMPLE 6

This example shows preparation of a thermoset polymer by reacting adicyclopentadiene oligomer comprising about 58.43% dicyclopentadiene,43.75% tricyclopentadiene and 5.05% tetracyclopentadiene (analyzed byG.C.), and tetramethylcyclotetrasiloxane (ratio of carbon-carbon doublebonds to hydrosilane groups of 0.86:1).

A complex of 0.0076 g of chloroplatinic acid and 21.71 g (0.12 mole) ofthe dicyclopentadiene oligomer was prepared by heating the two materialsunder a dry nitrogen blanket for one hour at 50° C.Tetramethylcyclotetrasiloxane (16.10 g, 0.07 mole) was added to theyellow complex (complex temperature was 71° C.). The reaction exothermedto 153° C. in 8 seconds. The yellow solution was cooled to 30° C.,poured into Teflon coated slotted molds and cured at 150° C./16 hoursand 200° C./4 hours. The 1/2"×3"×1/8" test pieces were removed from themold and post cured at 100° C./0.5 hours, 150° C./0.5 hours, 200° C./2hours, 225° C./2 hours, 250° C./2 hours and 280° /16 hours.

The final polymer was a hard glassy solid with a glass transitiontemperature of 250° C. and the weight loss by thermogravimetric analysisstarted at 500° C.

EXAMPLE 7

This example shows the preparation of a molded article comprising athermoset polymer, by partially reacting dicyclopentadiene andtetramethylcyclotetrasiloxane (ratio of carbon-carbon double bonds tohydrosilane groups of 1:1) to form a B stage type prepolymer, injectingthe B stage prepolymer into a mold, and heating to completepolymerization.

The catalyst, chloroplatinic acid (0.0148 g) was charged to a dried 25oz. reaction vessel and sealed. Under a nitrogen blanket 83.95 g (0.635mole) dicyclopentadiene was charged by syringe. The catalyst anddicyclopentadiene were heated for 90 minutes at 60° to 70° C. giving ayellow solution which was cooled to 30° C. Tetramethylcyclotetrasiloxane(76.36 g, 0.317 mole) was added and an exothermic reaction started intwo minutes, eventually reaching 193° C. After cooling to 55° C., asample was injected into a 5"×5"×1/8" teflon lined aluminum mold. Thepolymer was polymerized at temperatures ranging from 120° to 280° C.under a blanket of nitrogen. Some electrical properties of the curedpolymer are given below:

    ______________________________________                                        Dielectric Constant                                                                            2.87        60     Hz                                                         2.83        1      MHz                                       Dissipation      0.0001      60     Hz                                        Factor           0.0002      100    KHz                                       Volume                                                                        Resistivity ohm-cm                                                                             1.6 × 10.sup.18                                        Dielectric       381                                                          Strength v/mil                                                                ______________________________________                                    

A sample of the Example 7 polymer was immersed in boiling water for fivedays. The sample weight increased 0.1%. The dimensions of the sample(6.75, 1.30 cm, 0.32 cm) were unchanged after the boiling watertreatment. The modulus/temperature curve and glass transitiontemperature (250° C.) were also unchanged by the boiling watertreatment.

EXAMPLE 8

This example shows preparation of a thermoset polymer by reactingdicyclopentadiene and a mixture of methylhydrocyclosiloxanes, with aratio of carbon-carbon double bonds to hydrosilane groups of 0.7:1.

Chloroplatinic acid (0.0035 g) was weighed into an 8 oz. reaction vesselunder a nitrogen blanket in a dry box and the septum was sealed. Drydicyclopentadiene (8.08 g) was injected into the reaction vessel by ahypodermic syringe. The contents of the reaction vessel were heated to60° to 65° C. for 1 hour, under a nitrogen blanket, and thechloroplatinic acid dissolved. Dry air was swept through the reactionvessel for 10 to 15 minutes and the contents were cooled to 31° C.Methylhydrocyclosiloxanes, consisting of 54% tetramethylcyclotetrasiloxane, 20% pentamethyl cyclopentasiloxane, 5% hexamethylcyclohexasiloxane, 19% higher methylhydrocyclosiloxanes (up toapproximately ((CH₃ (H)SiO--)₂₀), and 2% linear methylhydrosiloxanes,(total 11.93 g) were injected and the reaction exothermed to 179° C.After cooling the reaction product to 60° C., it was poured into ateflon coated stainless steel mold. The mold was placed into a vacuumoven and a vacuum applied (approximately 15 mm Hg pressure, vacuum pump)for 10 to 15 minutes. Then, the mold was heated under nitrogen for 6hours at 180° C., for 6 hours at 225° C., for 2 hours at 235° C., andfor 4 hours at 285° C.

The polymer of this example exhibits thermoset behavior when polymerizedat 225° C. The polymer does not have a melting point, but softens at100° C. to a soft extendable elastomer. The polymer is a tough, leatherlike solid at room temperature. It is flexible enough to be twisted 360°before tearing.

EXAMPLE 9

This example shows preparation of a thermoset polymer by reactingdicyclopentadiene and methylhydrocyclosiloxanes in the same manner as inexample 8, except that the monomers were used in amounts such that theratio of carbon-carbon ratio of carbon-carbon double bonds tohydrosilane groups was 0.85:1 and the final heating was for 15 hours at130° C., for 6 hours at 160° C., for 16 hours at 180° C., for 4 hours at200° C., and for 4 hours at 225° C.

The thermoset polymer formed after heating to 225° C. was tougher thanthat from example 8. This hard, solid polymer maintains a high modulusup to 200° C. and exhibits elastomeric behavior when heated to 235° C.

EXAMPLE 10

This example shows preparation of a thermoset polymer by reactingdicyclopentadiene and methylhydrocyclosiloxanes in the same manner as inexample 9, except that the monomers were used in amounts such that theratio of carbon-carbon double bonds to hydrosilane groups of 1.15:1 andthe final heating was for 4 hours at 150° C., for 2 hours at 235° C.,and for 4 hours at 285° C.

EXAMPLE 11

This example shows preparation of a thermoset polymer by reactingdicyclopentadiene and methylhydrocyclosiloxanes in the same manner as inexample 10, except that the monomers were used in amounts such that theratio of carbon-carbon double bonds to hydrosilane groups of 1.30:1.

All the polymers produced in examples 9 to 11 exhibited thermosetcharacteristics and did not melt or lose their shape at temperaturesbelow the decomposition points of the polymers (400° to 500° C.).Polymers prepared from reactants having a carbon-carbon doublebond:hydrosilane equivalents ratio near 1:1 were post-cured at 285° to300° C. to increase their glass transition temperature to the 260° to300° C. range. The cross-link density of such polymers was high enoughto prevent segmental motion and network deformation.

EXAMPLE 12

This example shows preparation of a thermoset polymer by reactingdicyclopentadiene and methylhydrocyclosiloxanes in the same manner as inexample 8, except that the monomers were used in amounts such that theratio of carbon-carbon double bonds to hydrosilane groups was 1.46:1 andthe final heating was for 6 hours at 150° C., for 6 hours at 200° C.,for 2 hours at 235° C., and for 4 hours at 285° C.

This example demonstrates polymerization in the transition range fromthermoset behavior to thermoplastic behavior. When polymerized up to200° C., the sample softened to a highly compressible elastomer at about120° to 125° C. When the sample was post-cured at 285° C., the glasstransition temperature was raised to only 200° C. The degree ofcross-linking was limited by available hydrosilane groups.

EXAMPLE 13

This example shows preparation of a thermoplastic polymer by reactingdicyclopentadiene and methylhydrocyclosiloxanes in the same manner as inexample 9, except in amounts such that the ratio of carbon-carbon doublebonds to hydrosilane groups was 1.61:1 and the final heating was for 6hours at 150° C., for 6 hours at 200° C., for 8 hours at 235° C., andfor 4 hours at 285° C.

EXAMPLE 14

This example shows preparation of a thermoplastic polymer by reactingdicyclopentadiene and methylhydrocyclosiloxanes in amounts such that theratio of carbon-carbon double bonds to hydrosilane groups was 1.75:1.

A catalyst solution containing 600 ppm chloroplatinic acid was preparedby heating 0.0953 g of chloroplatinic acid with 158.8 gdicyclopentadiene to 70° C. for 1.5 hours in a sealed 8 ounce reactionvessel, under nitrogen. A 150 ppm chloroplatinic acid solution wasprepared by diluting 30 g of the above catalyst solution with 90 g ofdicyclopentadiene. A portion of the resultant chloroplatinic acidsolution (7.92 g) was weighed into a 7 inch reaction vessel with 4.59 gof dicyclopentadiene, making a 95 ppm concentration of chloroplatinicacid in dicyclopentadiene (0.185 gram equivalent of olefin). Then, 7.21g (0.106 hydrosilane equivalents) of methylsiloxanes (described inexample 10) were injected into the sealed reaction vessel at 23° C. Thereaction mixture was heated to 36° C. and a slight exotherm raised thetemperature to 60° C., where the mixture became viscous. A vacuum (15 mmHg) was applied to the contents of the reaction vessel at 45° C. for 10minutes to pull gas out of the reaction product. The product was pouredinto a teflon coated stainless steel mold and heated in a nitrogenblanket for 6 hours at 150° C., for 20 hours at 200° C., and for 6 hoursat 225° to 235° C. The 3"×1/2"×1/8" specimens removed from the mold weretransparent, hard solid with a melting point of 117° to 125° C. Thissolid could be ground into a crystalline powder.

The polymers of examples 13 and 14 do not form a complete polymericnetwork, even when they are polymerized at 225° to 235° C. They arecompletely thermoplastic and form a viscous, flowable liquid above theirmelting points. The solids can be ground into powder.

The properties of the polymers prepared in examples 8 to 14 are shown inthe following Table.

    __________________________________________________________________________    Organosilicon Polymers (Examples 11 to 17)                                    Dicyclopentadiene/Methylhydrocyclosiloxane                                                    Example No.                                                                   8   9   10  11   12    13     14                              __________________________________________________________________________     ##STR3##       0.70                                                                              0.85                                                                              1.15                                                                              1.30 1.46  1.61   1.75                            Chloroplatinic Acid Catalyst                                                                  175 174 178 177  179   181     95                             (ppm)*                                                                        Max. Polymerization Temp.                                                                     225 225 150 150  200   235    225                             (°C.)    (285)       (285)                                                                              (285)                                        Melting/Softening Point                                                                       SP 100                                                                            300 300 300  SP 120-125                                                                          MP 120-125                                                                           MP 117-125                      Glass Transition Temp. (°C.)                                           Mechanical      100 235 155 135 (210)                                                                          120 (200)                                                                           --     --                              Thermal DSC**   --  --  --  108   88   --     --                              Initial Weight Loss TGA,                                                      °C., (% residue, 1000° C.)                                      N.sub.2         --  --  --  460 (43.5)                                                                         460 (45.9)                                                                          450 (44.1)                                                                           500 (47.0)                      Air             --  --  --  470 (35.6)                                                                         470 (33.7)                                                                          450 (34.0)                                                                           500 (33.4)                      __________________________________________________________________________     *Calculated by dividing the total weight of the dry chloroplatinic acid b     the total weight of all the reactants.                                        **Differential Scanning Calorimeter.                                     

EXAMPLE 15

This example shows preparation of a graphite fiber composite.

Chloroplatinic acid (0.0185 g) was weighed into a reaction vessel in adry box and the reaction vessel was sealed. Dicyclopentadiene (47.15 g,0.357 mole, 0.714 equivalents) was injected into the reaction vessel andthe mixture was heated with stirring to 60° C. for 1 hour. After coolingto 36° C., tetramethylcyclotetrasiloxane (44.67 g) was injected. In twominutes, the sample exothermed to 192° C. The product was cooled andinjected into a teflon lined mold 5"×5"×1/8" containing ten 5"×5" sheetsof square woven graphite fiber cloth. The loaded mold was heated in anitrogen blanketed oven for 15 hours at 130° C., for 6 hours at 160° C.,and for 12 hours at 180° C. The resulting composite had good flexuralstrength (68,000 psi) and modulus (4.7×10⁶ psi).

While this invention has been described with respect to specificembodiments, it should be understood that these embodiments are notintended to be limiting and that many variations and modifications arepossible without departing from the scope of this invention.

What is claimed is:
 1. A process for preparing an organosiliconprepolymer comprising partially reacting, in the presence of ahydrosilation catalyst, (a) a cyclic polysiloxane or tetrahedralsiloxysilane containing at least two .tbd.SiH groups and (b) apolycyclic hydrocarbon polyene having in its rings at least twochemically distinguishable carbon-carbon double bonds, wherein 30% to65% of the .tbd.SiH groups are reacted, the ratio of carbon-carbondouble bonds in the rings of (b) to .tbd.SiH groups in (a) is greaterthan 0.5:1 and up to 1.8:1, and at least one of the compounds (a) and(b) has more than two reactive sites.
 2. The process of forming anorganosilicon prepolymer as claimed in claim 1, wherein thesilicon-containing reactant (a) is: ##STR4## wherein R, which can be thesame or different, is hydrogen or a substituted or unsubstituted alkyl,alkoxy, aromatic or aryloxy radical, n is an integer from 3 to about 20,and R is hydrogen on at least two of the silicon atoms in the molecule;or is: ##STR5## wherein R is as defined above and is hydrogen on atleast two silicon atoms in the molecule, and the polycyclic polyene isselected from the group consisting of dicyclopentadiene,tricyclopentadiene and methyl dicyclopentadiene.
 3. The process offorming an organosilicon prepolymer as claimed in claim 1, wherein thehydrosilation catalyst is a platinum-containing catalyst and the ratioof carbon-carbon double bonds in the rings of (b) to .tbd.SiH groups in(a) is in the range of about 0.7:1 up to about 1.3:1.
 4. The process offorming an organosilicon prepolymer as claimed in claim 2, wherein thehydrosilation catalyst is chloroplatinic acid and the ratio ofcarbon-carbon double bonds in the rings of (b) to .tbd.SiH groups in (a)is in the range of from about 0.8:1 up to about 1.1:1.
 5. The process ofclaim 1 wherein the reaction is discontinued at the point where 30 to65% of the .tbd.SiH groups have reacted.
 6. The process of forming acrosslinked organosilicon polymer consisting essentially of (a)preparing an organosilicon prepolymer according to the process of claim1 and (b) curing, in the presence of a hydrosilation catalyst, theorganosilicon prepolymer so as to form a crosslinked organosiliconpolymer.
 7. The process of forming a crosslinked organosilicon polymerconsisting essentially of providing an organosilicon prepolymer, whereinthe organosilicon prepolymer is the partial reaction product of (a) acyclic polysiloxane or a tetrahedral siloxysilane containing at leasttwo .tbd.SiH groups and (b) a polycyclic hydrocarbon polyene having inits rings at least two chemically distinguishable carbon-carbon doublebonds, the ratio of carbon-carbon double bonds in the rings of (b) to.tbd.SiH groups in (a) is greater than 0.5:1 and up to 1.8:1, at leastone of the compounds (a) and (b) has more than two reactive sites, and30 to 65% of the .tbd.SiH groups are reacted and curing theorganosilicon prepolymer in the presence of a hydrosilation catalyst toform a cross-linked organosilicon polymer.
 8. The process of forming acrosslinked organosilicon polymer as claimed in claim 7, wherein thesilicon-containing reactant (a) is: ##STR6## wherein R, which can be thesame or different, is hydrogen or a substituted or unsubstituted alkyl,alkoxy, aromatic or aryloxy radical, n is an integer from 3 to about 20,and R is hydrogen on at least two of the silicon atoms in the molecule;or is: ##STR7## wherein R is as defined above and is hydrogen on atleast two silicon atoms in the molecule.
 9. The process of forming acrosslinked organosilicon polymer as claimed in claim 8, wherein thepolycyclic polyene is selected from the group consisting ofdicyclopentadiene, tricyclopentadiene and methyl dicyclopentadiene. 10.The process of forming a crosslinked organosilicon polymer as claimed inclaim 7, wherein the hydrosilation catalyst is a platinum-containingcatalyst and the ratio of carbon-carbon double bonds in the rings of (b)to .tbd.SiH groups in (a) is in the range of about 0.7:1 up to about1.3:1.
 11. The process of forming a crosslinked organosilicon polymer asclaimed in claim 9, wherein the hydrosilation catalyst is chloroplatinicacid and the ratio of carbon-carbon double bonds in the rings of (b) to.tbd.SiH groups in (a) is in the range of from about 0.8:1 up to about1.1:1.
 12. The process of forming a fiber reinforced composite materialcomprising: (i) impregnating with an organosilicon prepolymer up to 80%,by weight of the resultant fiber reinforced composite material, fibrousreinforcement selected from the group consisting of glass, carbon,metallic, ceramic or synthetic polymer fibers, or fiber mat; and (ii)curing, in the presence of a hydrosilation catalyst, the prepolymer toform a fiber reinforced composite material, wherein the organosiliconprepolymer is the partial reaction product of (a) a cyclic polysiloxaneor a tetrahedral siloxysilane containing at least two .tbd.SiH groupsand (b) a polycyclic hydrocarbon polyene having in its rings at leasttwo chemically distinguishable carbon-carbon double bonds, wherein theratio of carbon-carbon double bonds in the rings of (b) to .tbd.SiHgroups in (a) is greater than 0.5:1 and up to 1.8:1, at least one of thecompounds (a) and (b) has more than two reactive sites and wherein 30%to 65% of the .tbd.SiH groups are reacted.
 13. The process of forming afiber reinforced composite material as claimed in claim 12, wherein thesilicon-containing reactant (a) is: ##STR8## wherein R, which can be thesame or different, is hydrogen or a substituted or unsubstituted alkyl,alkoxy, aromatic or aryloxy radical, n is an integer from 3 to about 20,and R is hydrogen on at least two of the silicon atoms in the molecule;or is: ##STR9## wherein R is as defined above and is hydrogen on atleast two silicon atoms in the molecule.
 14. The process of forming afiber reinforced composite material as claimed in claim 13, wherein thepolycyclic polyene is selected from the group consisting ofdicyclopentadiene, tricyclopentadiene and methyl dicyclopentadiene. 15.The process of forming a fiber reinforced composite material as claimedin claim 12, wherein the hydrosilation catalyst is a platinum-containingcatalyst and the ratio of carbon-carbon double bonds in the rings of (b)to .tbd.SiH groups in (a) is in the range of about 0.7:1 up to about1.3:1.
 16. The process of forming a fiber reinforced composite materialas claimed in claim 14, wherein the hydrosilation catalyst ischloroplatinic acid and the ratio of carbon-carbon double bonds in therings of (b) to .tbd.SiH groups in (a) is in the range of from about0.8:1 up to about 1.1:1.
 17. The process of forming a fiber reinforcedcomposite material as claimed in claim 12, wherein step (i) comprisescharging a mold containing the fiber reinforcement with theorganosilicon prepolymer.
 18. The process of forming a fiber reinforcedcomposite material as claimed in claim 12, wherein step (i) comprisesinjecting the organosilicon prepolymer into a mold containing the fiberreinforcement.
 19. The process of forming a fiber reinforced compositematerial comprising:(i) forming a prepolymer by partially reacting, inthe presence of a hydrosilation catalyst, (a) a cyclic polysiloxane ortetrahedral siloxysilane containing at least two .tbd.SiH groups and (b)a polycyclic hydrocarbon polyene having in its rings at least twochemically distinguishable carbon-carbon double bonds, to the extentthat 30% to 65% of the .tbd.SiH groups are reacted, wherein the ratio ofcarbon-carbon double bonds in the rings of (b) to .tbd.SiH groups in (a)is greater than 0.5:1 and up to 1.8:1, and at least one of the compounds(a) and (b) has more than two reactive sites; (ii) impregnating with theorganosilicon prepolymer up to 80%, by weight of the resultant fiberreinforced composite material, fibrous reinforcement selected from thegroup consisting of glass, carbon, metallic, ceramic or syntheticpolymer fibers, or fiber mat; and (iii) curing, in the presence of ahydrosilation catalyst, the prepolymer to form a fiber reinforcedcomposite material.
 20. The process of forming a fiber reinforcedcomposite material as claimed in claim 12, wherein thesilicon-containing reactant (a) is: ##STR10## wherein R, which can bethe same or different, is hydrogen or a substituted or unsubstitutedalkyl, alkoxy, aromatic or aryloxy radical, n is an integer from 3 toabout 20, and R is hydrogen on at least two of the silicon atoms in themolecule; or is: ##STR11## wherein R is as defined above and is hydrogenon at least two silicon atoms in the molecule; the polycyclic polyene isselected from the group consisting of dicyclopentadiene,tricyclopentadiene and methyl dicyclopentadiene; the hydrosilationcatalyst is a platinum-containing catalyst; and the ratio ofcarbon-carbon double bonds in the rings of (b) to .tbd.SiH groups in (a)is in the range of about 0.7:1 up to about 1.3:1.
 21. The process offorming a fiber reinforced composite material as claimed in claim 20,wherein the hydrosilation catalyst is chloroplatinic acid and the ratioof carbon-carbon double bonds in the rings of (b) to .tbd.SiH groups in(a) is in the range of from about 0.8:1 up to about 1.1:1.